Recall - Replace Vehicle Fuel Tank
12-010March 20, 2012
Applies To:
2012 Pilot-Check the iN VIN status for eligibility
Safety Recall: Fuel Tank
(Supersedes 12-010, dated February 17, 2012, to revise the information marked by the black bars and asterisks)
*REVISION SUMMARY
^ The WARRANTY CLAIM INFORMATION was updated.
^ An example of the customer letter was added.*
BACKGROUND
The fuel tank vapor control vent shut float valve may not have been properly welded inside the fuel tank and may allow fuel to enter the EVAP canister.
CUSTOMER NOTIFICATION
Owners of affected vehicles will receive a notification of this campaign in March 2012.
Do an iN VIN status inquiry to make sure the vehicle is shown as eligible.
In addition, check for a punch mark above the third character of the engine compartment VIN. A punch mark in that location means this campaign has already been completed.
Some vehicles affected by this campaign may be in your new or used vehicle inventory. As a matter of federal law, these vehicles must be repaired before they are sold.
Should a dealership sell an unrepaired vehicle that subsequently causes an injury or damage because of the recalled item, the dealership will be solely responsible to the damaged party, and will be required to defend and indemnify American Honda for any resulting claims. To see if a vehicle in inventory is affected by this campaign, do a VIN status inquiry before selling it.
CORRECTIVE ACTION
Inspect and record the fuel tank vapor control vent shut float valve number located on the top of the fuel tank. If the lot number is listed in the affected lot numbers, replace the tank. If you replace the tank, check the fuel tank vapor control vent shut float valve in the original tank. If the valve is not securely mounted, replace the EVAP canister.
PARTS INFORMATION
TOOL INFORMATION
Fuel Sender Wrench: T/N 07AAA-S0XA100
KTC Trim Tool Set: T/N S0JATP2014
Fuel Tank Hand Pump (or equivalent):
T/N TEMFM2100
Powertrain Lift (or equivalent): T/N 0TC1595
REQUIRED MATERIALS
Honda 2 Threadlock (or equivalent): P/N 08713-0002
(One tube is enough to repair about four vehicles.)
WARRANTY CLAIM INFORMATION
Failed Part: P/N 17044-SZA-A10
Defect Code: 5VCOO
Campaign Code: S2500
Skill Level: Repair Technician
*Diagnostic Trouble
Code: Enter the four-digit code from the
fuel tank in the first DTC field, see
step 14 under INSPECTION
PROCEDURE.*
INSPECTION PROCEDURE
NOTE:
This procedure is an outline form that you can also use as a checklist for the repair. If you need more details on the procedures listed below, bookmark them in the appropriate service manual, or view them online:
^ Fuel Pressure Relieving
^ Battery Terminal Disconnection and Reconnection
^ Fuel Line/Quick-Connect Fitting Removal
^ Second Row Seat Removal/Installation
^ Fuel Tank Unit Removal and Installation
^ Fuel Tank Draining
^ Exhaust Pipe and Muffler Replacement
^ Propeller Shaft Removal
^ EVAP Canister Replacement
^ Fuel Tank Replacement
1. Relieve the fuel pressure. After you relieve the fuel pressure, replace the retainer (blue/green) and reconnect the fuel line.
2. Remove the left side of the second row seat.
3. Remove the fuel tank unit.
4. Drain the fuel tank, then reinstall the fuel tank unit without reconnecting the connector or the fuel line.
5. Raise the vehicle on a lift.
6. Remove the exhaust pipe and mufflers.
7. 4WD: Remove the propeller shaft. Make sure you make reference marks across both ends of the propeller shaft and the companion flanges.
8. Remove the EVAP canister cover.
9. Remove the fuel tank protector.
10. Disconnect the quick-connector fitting and the hoses on the fuel tank. Slide back the clamps, then twist them as you pull to avoid damaging them.
NOTE:
Make sure that you review the precautions and notes in the Fuel Line/Quick-Connect Fitting Precautions section of the service manual.
11. Place a jack or other support under the fuel tank. NOTE: Make sure you strap the tank to the jack or support.
12. Remove the fuel tank strap bolts and the straps.
13. Remove the fuel tank.
14. Check the four digits of the lot number that follow STX on the fuel tank vapor control vent shut float valve, and write them on the repair order. If you have one of the lot numbers listed below, the tank is NG.
^ If the tank is NG, you must replace the fuel tank, and go to step 15 to check the vapor control vent shut float valve.
^ If the four digits of the lot number on the fuel tank vapor control vent shut float valve are not in the list above, the vehicle is OK. Go to REPAIR PROCEDURE - FUEL TANK REPLACEMENT AND INSTALLATION to reinstall the fuel tank.
NOTE:
The warranty administrator will need to enter the lot number in the first DTC field of the warranty claim.
15. Remove the fuel tank unit, and reach inside the fuel tank as shown to check that the vapor control vent shut float valve is securely mounted to the top of the tank.
NOTE:
^ Make sure you only inspect a maximum of three fuel tanks a day to limit your exposure to fuel fumes in the tank.
^ If you get fuel on your clothing, make sure to change your clothes, and properly store/clean the fuel soaked clothing to avoid any potential risk of fire.
Do not try to reach straight in as you may not be able to reach the vapor control vent shut float valve and your arm could get stuck.
^ If the vapor control vent shut float valve is securely mounted (the valve doesn't move when you try to shake it) replace the fuel tank only.
Go to REPAIR PROCEDURE - FUEL TANK REPLACEMENT AND INSTALLATION.
^ If the vapor control vent shut float valve is not securely mounted, fuel may have contaminated the EVAP canister. Replace the fuel tank and the EVAP canister. Do REPAIR PROCEDURE - EVAP CANISTER REPLACEMENT.
REPAIR PROCEDURE - EVAP CANISTER REPLACEMENT
NOTE:
This procedure is an outline form that you can also use as a checklist for the repair. If you need more details on the procedures listed below, bookmark them in the appropriate service manual, or view them online:
^ Fuel Tank Unit Removal and Installation
^ EVAP Canister Replacement
1. Remove the EVAP canister.
2. Assemble the new EVAP canister using these new parts:
^ EVAP canister vent shut valve
^ Fuel tank pressure sensor (FTP)
^ Fuel tank pressure sensor retainer
3. Replace EVAP canister drain hoses D and E. Make sure you clean any gasoline out of the lines.
4. Reinstall the EVAP canister, then go to REPAIR PROCEDURE - FUEL TANK REPLACEMENT AND INSTALLATION.
REPAIR PROCEDURE- FUEL TANK REPLACEMENT AND INSTALLATION
NOTE:
This procedure is an outline form that you can also use as a checklist for the repair. If you need more details on the procedures listed below, bookmark them in the appropriate service manual, or view them online:
^ Fuel Tank Replacement
^ Fuel Tank Unit Removal and Installation
^ Fuel Line/Quick-Connect Fitting Removal
^ Fuel Line/Quick-Connect Fitting Installation
^ Exhaust Pipe and Muffler Replacement
^ Propeller Shaft Installation
^ Battery Terminal Disconnection and Reconnection
^ Second Row Seat Removal/Installation
1. If you are directed to replace the fuel tank, remove the fuel tank unit from the original tank, and replace the fuel tank.
2. Temporarily attach a new base gasket to the fuel tank unit, then partially insert the fuel tank unit into the new fuel tank.
NOTE:
^ Be careful not to damage the new base gasket.
^ Be careful not to bend the fuel gauge sending unit.
Do not coat the base gasket with oil.
3. With the fuel tank unit partially inserted in the fuel tank, transfer the base gasket from the fuel tank unit to the fuel tank.
4. Align the marks on the fuel tank and the fuel tank unit, then insert the fuel tank unit into the fuel tank until the unit rests on top of the base gasket.
NOTE:
To prevent a fuel leak, check the base gasket, either visually or by hand, to make sure it is not pinched.
5. Using a new locknut and locknut plate, tighten the nut by hand.
NOTE:
Before tightening, align the mark on the locknut with the start of the threads.
6. Raise the fuel tank.
7. Reinstall the fuel tank straps and strap bolts.
8. Reconnect the quick-connector fittings and the hoses. Make sure you replace the retainer (orange) on the vent line located at the rear of the tank.
9. Reinstall the fuel tank protector and torque the nuts to 9.8 N.m (7.2 lb-ft).
10. Reinstall the EVAP canister cover.
11. 4WD: Reinstall the propeller shaft using the eight new driveshaft bolts and the center support bearing with two new bolt-washers. Torque the bolts:
^ Driveshaft bolts - 72 N.m (53 lb-ft)
^ Center support bearing bolt-washers - 39 N.m (29 lb-ft)
^ Propeller shaft protector (reuse bolts) - 22 N.m (16 lb-ft)
12. Reinstall the exhaust pipe using three new exhaust nuts and a new gasket. Torque the nuts to 33 N.m (25 lb-ft).
13. Lower the vehicle.
14. Tighten the fuel tank unit locknut to 70 N.m (52 lb-ft).
NOTE:
^ After tightening, make sure the marks are still aligned.
^ After installation, check the base gasket, visually or by hand, that it is not pinched.
15. Connect the fuel tank unit connector.
16. Reconnect the quick-connect fitting to the tank unit using a new retainer.
17. Pour the removed fuel back into the fuel tank.
18. Do the battery reconnection procedure.
19. Restore the fuel pressure by turning the ignition switch to ON (II) (but do not start the engine) for about 2 seconds. Repeat two or three times.
20. Check for fuel leaks.
21. Install the access panel on the floor.
22. Install the second row seat. Coat the bolts with the threadlock, then torque them to 47 N.m (35 lb-ft) in the order shown.
23. Center-punch a completion mark above the third character of the engine compartment VIN.
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